Transmission, With A CIRCLIP Or A Plastic Cover: Assembly

Press the new grooved ball bearing INPUT SHAFT OVERVIEW onto the input shaft.

-- First insert the input shaft -1-, output shaft for 5th/6th gears -2- together with selector rods with selector forks -3-, reverse gear selector fork -4- and reverse shaft -5-.

Fig 1: Inserting Input Shaft, Output Shaft For 5Th/6Th Gears Together With Selector Rod, Shift Fork And Reverse Shaft

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Pay attention to the different bearing for the reverse gear selector fork.

Fig 2: The reverse gear selector fork -1- is mounted on the axle -2- behind the 5th and 6th gear selector shaft -3-.

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Fig 3: The reverse gear selector fork -1- is mounted on the selector shaft with the 5th and 6th gear selector fork -2-.

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Continuation for Vehicles:

-- Then, install the differential -1-.

Fig 4: Inserting Differential, Input Shaft & Output Shaft

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NOTE:

A 2nd technician is needed to help install the shafts into the clutch housing.

-- Hold the output shaft for 1st through 4th gear -3- and the selector shaft with selector forks -4- with the right hand.

-- Slightly lift the differential with the left hand.

-- Have the second technician lift the input shaft, the 5th/6th gear output shaft and reverse gear -2- together with the reverse shaft slightly at the same time.

-- Install the 1st to 4th gear output shaft in the -direction of the arrow-.

Places of input shaft, output shafts and final drive gear/differential must engage.

-- Together with a second technician, now place the shafts and differential in their bearing seats.

-- Install the bracket 30-211A for the input shaft to the clutch housing.

Fig 5: Identifying Bolt, Bracket 30-211A & Special Tool VW 353

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NOTE:

The clutch housing is shown in the illustration rotated 180°.

-- Install the bolt -A- just far enough until the input shaft starts to lift.

Fig 6: Flattened Areas on the Grooved Ball Bearing and Bearing Seat in the Transmission Housing, Approximately from Transmission Build Date 21 February 2008

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There is a flattened area on the grooved ball bearing and the bearing mount.

If the flattened areas -A and B- are present, do not insert any washers above and below the grooved ball bearing. Refer to GROOVED BALL BEARING CHANGES .
The flattened sides -A- on the grooved ball bearing and on the bearing mount -B- must align in the transmission housing.

-- Mark the flattened side with color.

-- Transfer the marks to the upper area of the grooved ball bearing and to the upper area of the transmission housing bearing mount (next illustration).

-- Heat the transmission housing in the area near the bearing seat for the grooved ball bearing/input shaft to approximately 100°C (212°F) for 10 minutes using a heat gun, for example, V.A.G 1416.

NOTE:

It is necessary to heat the transmission housing so that the grooved ball bearing is not damaged when the housing is being installed.

Apply sealing paste AMV 188 200 03 evenly onto the sealing surface of the clutch housing.

Align the mark on the grooved ball bearing -A- with the mark on the transmission housing -B- and mount the transmission housing.

Fig 7: Aligning Mark On Grooved Ball Bearing With Mark On Transmission Housing

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-- Install the transmission housing and tighten the bolts -A, B and C- to specification.

If the steel bolts (outer hex head) are the replacement part, pay attention to the allocation:

Fig 8: Allocation Of Bolts As Replacement Parts

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A - Bolt with a permanent washer

B - Bolt without a washer

C - Bolt with a permanent washer

-- Install the grooved ball bearing/input shaft locking ring -1-.

Fig 9: Identifying Circlip & Special Tool VW 309

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-- Remove the bracket 30-211 A from the input shaft.

-- Install the selector shaft lock sleeve all the way onto the tool, refer to Figure.

-- Turn the transmission with the opening for the gear shift unit shaft in assembly stand upward.

-- Install the gear shift unit shaft -1- into the lower bearing -2- and into the selector forks -3-.

Fig 10: Inserting Selector Shaft Into Lower Bearing And Into Shift Forks

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NOTE:

The cover is not shown in the illustration.

-- Push the gear shift unit shaft -1- against the retaining sleeve -2- in the -direction of the arrow- and guide is through the selector fork all the way down using the shift finger -3-.

Fig 11: Pressing Selector Shaft Against Lock Sleeve And Guide Downward With Shift Finger

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The gear shift unit cover -4- must be parallel to the bolting surface on the transmission housing.
It must be possible to move the gear shift shaft easily (forward and backward).

NOTE:

If the gear shift unit cover is at an angle to the bolting surface, then the gear shift shaft is not installed into the lower bearing.

-- Tighten the bolts -3- for the gear shift unit cover -4-.

Fig 12: Identifying Back-Up Lights Switch, Mounting Screw, Bolts & Selector Shaft